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Cryogenic and Superconducting Technologies for 3.2 MW Hybrid-Electric Aircraft Propulsion T.J. Haugan 1, G.Y. Panasyuk 2 1 Air Force Research Laboratory, AFRL/RQQM, Wright-Patterson AFB, OH 45433 2 UES Inc., Dayton OH 45432 3.2 MW Drivetrains 3 MW Components 3 MW Generators The major components of 3.2 MW drivetrains were considered for both cryogenic and Cu-wire, however the associated power electronics and mechanical gearing were not estimated yet. A Prius style drive-train is 4x lighter for cryogenic than Cu-wire. A Chevy-volt style drive-train with cryogenic components is estimated to be 3x lighter, increasing the range for cruise in electric drive 2x and reducing fuel cost 3x. 3 MW Li-Batteries *J. Felder, et al, NASA-Glenn, ISABE_ 2011_1340 DISTRIBUTION A. Approved for public release. Distribution unlimited. 3.2 MW Aircraft deHavilland Dash 8 de Havilland Bombadier Dash 8: DHC-8-100 series (Canada) Pratt-Whitney PW110, 1.4 MW continuous - PW121 Mass = 425 kg - Power = 1.603 MW continuous - Power density = 3.77 kW/kg http://en.wikipedia.org/wiki/Pratt_%26_Whitney_Canada_PW100 http://en.wikipedia.org/wiki/Turbo http://en.wikipedia.org/wiki/Bombardier_Dash_8http://en.wikipedia.org/wiki/Bombardier_Dash_8 propprop DHC-8-100 Capacity 37-39 passengers Typical Payload7511 lbs Range1174 miles Motors2 PW121 Motor Weight1874 lbs Max. Fuel Size1003 U.S. gal Max. Fuel Weight6039 lbs Maximum Weight36661 lbs * Assume power density = 4 kW/kg ** Energy density = 400 Wh/kg DHC-8- 100B Hybrid Cu-Wire Hybrid Cryo 3.2 MW Engine (2 PW121) 1874 lb 1.83 MW Electric Motor/Generator 1010 lb*101 lb 2.6 MW Electric Motor 1439 lb*144 lb 227 MJ Li Battery413 lb** Extra Machine Weight (w battery) 02862 lb658 lb Fuel Weight (Max.)6039 lbs3446 lb5381 lb 3.2 MW Prius-Style Drivetrain Cryo 4x lighter Cryo 60% longer range (3.2 MW) (1.8 MW ) (2.6 MW) -Similar to General Motors' Chevy Volt drive train, the DA36 E-Star uses a serial hybrid electric drive train - Siemens scientists are currently working on a new electric motor that is expected to be five times lighter than conventional drives. In two years, another aircraft is expected to be equipped with an ultra-light electric drive. http://www.siemens.com/ 70 kW Electric Motor and Drivetrain 70 kW Chevy-Volt Style Drivetrain, Siemens DA36 E-Star (227 MJ) (1.8 MW) (1.55 MW) (3.2 MW) (2.8 GJ) DHC-8- 100B Hybrid Cu-Wire* Hybrid Cryo Combustion Engines 1874 lb (3.2 MW) 1054 lb (1.8 MW) 1054 lb (1.8 MW) 1.55 MW Electric Motor/Generator 833 lb*83 lb 3.2 MW Elec- Motor1721 lb*172 lb Cooling ?38 lb H 2-liq /hr or 88 lb N 2-liq /hr Machine Weight1,874 lb3,608 lb1,310 lb Fuel Mix Max.6,039 lb gas 772 lb gas 3,533 lb battery 772 lb gas 5,831 lb battery Machine+Fuel Max.7,913 lb Range @ Power avg 1,174 miles gas 150 miles gas 69 miles elec ** 150 miles gas 126 miles elec ** Fuel Cost @ Power avg (per 100 miles*passenger) $6.51$1.27$1.14 * Assume power density = 4 kW/kg ** Battery energy density = 400 Wh/kg - Electric Cu-wire drivetrain efficiency = 90% (Tesla motors = 88%) - Combustion efficiency = 29% - HTS drivetrain efficiency = 99% - Electric cost = $1.8 per gal equiv. ($0.054/kW-h, Dayton Sept 2013) - JP-8 Fuel = $3.12 per gal (2012 avg) Cryo 3x lighter Range cryo-elec ~10% Range gas Fuel Cost 6x lower 3.2 MW Chevy-Volt-Style Drivetrain www.motortrend.com 0.2 MW Cu-Wire (Tesla Inc.) 1-35 MW -Superconductor (General Electric- MEPS) 1-30 MW Full- Superconducting (NASA-Glenn ) Cu-Wire1/2- Supercond HTS @ 77K Full- Supercondu ctor @20K* Weight Device (lb) 1554753132 Power Density (cont.) 4.1 kW/kg 8.8 kW/kg50 kW/kg Machine Efficiency (%) 959799.97 Waste Heat (cont.) 150 kW90 kW0.9 kW Waste Heat / Mass ( per hr) 540 MJ324 MJ3.3 MJ Waste Heat / Mass (MJ/kg*h) 0.370.320.03 CryoCooler Mass @ 3 MW (option) 66 lb cryo ? Non-cryo 238 lb* Liquid Cooling @ 3 MW (option) 23.7 lbs/h Liquid H 2 GOTCHA: Risk factor low for Cryo Machines GOTCHA: Weight reduced > 10x GOTCHA: Heat loss reduced > 100x * Assume Turbo-Brayton cryocooler 30% efficient, and power density = 3 kw/Kg Summary Energy densities = 400 Wh/kg achieved ! http://enviasystems.com Calculations -Cruise speed = 500 km/hr -Electric-drivetrain efficiency = 90% (Tesla Motors = 88%) -Power use = 22% of 3.2 MW Range elec = [Range-Max gas ]/Fuel-Max gas ]*Fuel Battery *[ elec / gas ]; where = drivetrain efificiency